CW16 Pneumatic Compactor Propel System Caterpillar

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Diesel engine exhaust contains products of combustion which may cause personal injury. Always start and operate the engine in a well ventilated area, and, if in an enclosed area, vent the exhaust to the outside.

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Personal injury can result from rotating and moving parts. Stay clear of all rotating and moving parts. Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified. The machine must be parked on a level surface and the engine stopped. Attach a "Do Not Operate" or similar warning tag to the start switch and controls before servicing, repairing, or making adjustments to the machine.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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Injury to personnel can result if they are not in the operator's view. Allow only essential personnel near the machine, and make sure the personnel are in the operator's view when testing, to prevent injury. Make sure checks are done in an open area.

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To prevent injury or death, never work under a machine while a test is being performed.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Specifications

Introduction

The propel pump is a tandem pump. The swashplate in each half of the pump is controlled with an electronic displacement control. Use this procedure to determine if the electronic displacement controls have the swashplates in the neutral position. If necessary, use this procedure to adjust the electronic displacement controls.

Required Tools

Illustration 1	g02571852

1. Connect each Tool (A2) to a Tool (A4).

2. Connect each Tool (A3) to a Tool (A4).

3. Connect each Tool (A4) to Tool (A1).

Illustration 2	g06026927

1. Connect Tool (C2) and Tool (C3) to Tool (C1).

2. Connect Tool (C2) to the USB port of Tool (B).

Test Preparation

1. Drive the machine to a smooth, horizontal surface.
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   Illustration 3	g06019489

2. Move propel lever (1) to the NEUTRAL position.

3. Move parking brake switch (2) to the ON position.
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   Illustration 4	g06019492

4. After the engine has operated at low idle for 5 minutes, move engine start switch (3) to the OFF position.
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   Illustration 5	g06019498

5. Unhook latch (5) at the rear of the engine compartment, and open engine hood (4).
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   Illustration 6	g06019509

6. Move hood support bracket (6) to support engine hood (4).
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   Illustration 7	g06026609

7. Loosen the set screw on needle valve (7) to disable the brakes. Rotate the needle valve clockwise to close the valve fully. Tighten the screw.
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   Illustration 8	g06026618
   Illustration 8 shows components removed to show obscured components.

8. Remove the plug from port "M4" (8) in the front section of the propel pump. Install Tool (D) in the "M4" port.

9. Connect Tool (A2) to Tool (D) in port "M4" (8).
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   Illustration 9	g06026622
   Illustration 9 shows components removed to show obscured components.

10. Remove the plug from port "M5" (9) in the front section of the propel pump. Install Tool (D) in the "M5" port.

11. Connect Tool (A2) to Tool (D) in port "M5" (9).
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    Illustration 10	g06028070

12. Mark the wires for identification. Disconnect the electrical harness assembly from solenoid (10) and solenoid (11).
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    Illustration 11	g06028075

13. Remove diagnostic port access cover (12).
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    Illustration 12	g06028078

14. Connect Tool (C3) to diagnostic connector (13).

Test Procedure

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Illustration 13	g06028085

1. Move engine start switch (3) into the ON position. When the "Wait to start engine" message disappears from display (14), move the engine start switch to the START position. Release the switch when the engine starts.

2. Monitor the hydraulic oil temperature on display (14). Operate the machine until the oil temperature reaches a minimum of 45 °C (113 °F).
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   Illustration 14	g06028093

3. Use gear select switch (15) to select "High" speed.

   Note: Two things indicate when the machine is in high speed. First, "High" will appear on the display. Second, three LED's next to gear select increase switch (15) will be illuminated.

4. Move parking brake switch (2) to the OFF position.

5. Launch the Plus+1^TM program on the computer to allow the engine to go into high idle.

   Note: First-time users need to perform the tasks in the Communication and Connections Wizard. This wizard allows the Windows^R operating system to recognize the USB device. Follow the on-screen instructions.

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   Illustration 15	g06028101

6. Read and understand the instructions in the "1" section.

7. Click the "Folder" icon (16) on the menu bar or click "Folder" icon (17) under "Open Diagnostics" file.

8. Select the proper diagnostic file for the machine.

9. Click the "Open" button.
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   Illustration 16	g06028109

10. Check "Active Codes" (20). Clear any active codes.

11. Select "Machine Control" (19) from the available ECM's.

12. Click "Target Calibrations" icon (18).
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    Illustration 17	g06028116

13. Under "Machine Controls" select "Hydraulics" (21).
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    Illustration 18	g06028230

14. Click "Piston Pump Neutral Test" (22).
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    Illustration 19	g06028237

15. Click "Enable" (23).
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    Illustration 20	g06028247

16. When "Value" (24) and "Target" (25) are "Enabled" (26) the Plus+1^TM program is launched.

17. Read differential pressure on Tool (A). Differential pressure should be less than 150 kPa (22 psi).

18. If the differential pressure is greater than 150 kPa (22 psi), go to "Adjustment Procedure". If the differential pressure is less than 150 kPa (22 psi) go to the next step.

19. After the engine has operated at low idle for 5 minutes, move engine start switch (3) to the OFF position.

20. Remove the tooling from port "M4" (8) and port "M5" (9).

21. Install plugs in port "M4" (8) and port "M5" (9). Tighten the plugs to a torque of 12 N·m (9 lb ft).

22. Connect the electrical harness assembly to solenoid (10) and solenoid (11).
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    Illustration 21	g06028256
    Illustration 21 shows components removed to show obscured components.

23. Remove the plug from port "M4" (27) in the rear section of the propel pump. Install Tool (D) in the "M4" port.

24. Connect Tool (A2) to Tool (D) in port "M4" (27).
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    Illustration 22	g06028261
    Illustration 22 shows components removed to show obscured components.

25. Remove the plug from port "M5" (28) in the rear section of the propel pump. Install Tool (D) in the "M5" port.

26. Connect Tool (A2) to Tool (D) in port "M5" (28).
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    Illustration 23	g06028267

27. Mark the wires for identification. Disconnect the electrical harness assembly from solenoid (29) and solenoid (30).

28. Move engine start switch (3) into the ON position. When the "Wait to start engine" message disappears from display (14), move the engine start switch to the START position. Release the switch when the engine starts.

29. Repeat Step 4 through Step 16 to relaunch the Plus+1^TM program.

30. Read differential pressure on Tool (A). Differential pressure should be less than 150 kPa (22 psi).

31. If the differential pressure is greater than 150 kPa (22 psi), go to "Adjustment Procedure". If the differential pressure is less than 150 kPa (22 psi) go to the next step.

32. Operate the engine at low idle for a few minutes.

33. After the engine has operated at low idle for 5 minutes, move engine start switch (3) to the OFF position.

34. Remove the tooling from port "M4" (27) and port "M5" (28).

35. Install plugs in port "M4" (27) and port "M5" (28). Tighten the plugs to a torque of 12 N·m (9 lb ft).

36. Connect the electrical harness assembly to solenoid (29) and solenoid (30).

37. Loosen the set screw on needle valve (7) to enable the brakes. Rotate the needle valve counterclockwise to open the valve fully. Tighten the screw.
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    Illustration 24	g06021588

38. Move hood support bracket (6) in the stored position. Close engine hood (4) and secure latch (5).

Adjustment Procedure

Note: A small movement of the adjustment mechanism is all that will be required. Larger movements may cause machine movement.

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Illustration 25	g06028612

1. To adjust the front propel pump. Hold adjustment screw (31) and loosen locknut (32). Watch the pressure gauges. Rotate the adjustment screw until the differential pressure is less than 150 kPa (22 psi).
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   Illustration 26	g06028625

2. To adjust the rear propel pump. Hold adjustment screw (34) and loosen locknut (33). Watch the pressure gauges. Rotate the adjustment screw until the differential pressure is less than 150 kPa (22 psi).